Full automation with complete flexibility

Requirement:

1. Processing of a wide range of parts – from recurring series and wear parts to individual parts and small series.
2. Fully automated production despite high component diversity.
3. Integration of a large-capacity drawer storage system (up to 1,700 parts).
4. Design and manufacture of customer-specific clamping devices and set-up parts.
5. Turnkey integration into an existing, previously manual production system.
6. Significant reduction in manual labour and monotonous tasks.
7. High process reliability for unmanned production – day and night.

Considerations:

• Use of a SPINNER U5-630 combined with a flexible automation cell.
• Development of all necessary clamping and set-up equipment specifically for the numerous different components.
• Storage solution with 14 levels for holding approx. 1,700 parts.
• Running in and optimisation of the machining processes for five representative sample components.
• Improvement of workplace quality through automation of monotonous tasks.

Solution:

At the heart of the system is a modern production cell based on a SPINNER U5-630 with an attached automation cell and a 14-level drawer storage system. This combination makes it possible to automatically manufacture an exceptionally wide range of components – from recurring wear parts to small series and individual parts.

All necessary clamping devices and set-up components were specially designed, manufactured and tested to meet the customer's requirements. The machining processes for five different components were run in advance and the complete solution was then integrated into the existing production facility on a turnkey basis.

Before implementation, production was heavily manual: monotonous tasks, person-dependent processes and machines that were no longer up to date. Thanks to the new system, production is now more economical, stable and largely unmanned – both during the day and at night.

However, the effect goes far beyond productivity: skilled workers can once again concentrate on value-adding activities – process optimisation, technological development and innovation. Production is becoming more attractive, modern and future-proof. The new system not only increases output, but also creates real freedom and increases motivation within the team.